Olmeca Project

Date: 30.03.2016

Scope
of
Project Management,
Detail-Engineering,
Construction Supervision
and
Pre-Commissioning Activities
for

Project:

Olmeca

by
Clariant Mexico S.A. de C.V., BU ICS

prepared by
Clariant Group Technology Services
Project Engineering
Mario Olvera
96400 Coatzacoalcos, Veracruz
Mexico

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Date: 30.03.2016

Table of Content

1.

Introduction and Project Scope .................................................................. 2

Definitions .................................................................................................... 5

Scope of Services ........................................................................................ 6

3.1

Project Management ....................................................................................... 6

3.2

Process Engineering ...................................................................................... 7

3.3

Equipment, Machines, Package Units ........................................................... 7

3.4

Layout Planning ............................................................................................. 8

3.5

Piping ............................................................................................................... 8

3.6

Electrical & Instrumentation Engineering ..................................................... 9

3.7

Civil Engineering ............................................................................................. 9

3.8

Checks of incoming Deliveries from Suppliers........................................... 11

3.9

Construction Supervision ............................................................................ 11

3.10

Pre-Commissioning ...................................................................................... 12

3.11

Start-up .......................................................................................................... 12

Documentation........................................................................................... 12

5.

Guidelines, Standards and Regulations .................................................. 13

Attachment 1: Important project milestones .................................................. 13

Attachment 2: Documentation ......................................................................... 13
Attachment 3: Existing Basic Engineering Package ..................................... 16
Attachment 5: P&IDs and Layouts ............................................................... 16
Attachment 6: Equipment list and spacifications data sheets.................... 16
Attachment 7: Piping List ............................................................................... 16

1.

Introduction and Project Scope

Clariant intends to build a EO & PO expansion at its site at Coatzacoalcos, Veracruz,

Mexico. The Basic Engineering phase will be completed by March 2016.
In the upcoming project phase a complete scope of services is requested, including
Project Management, Detail Engineering, Construction Supervision and PreCommissioning Activities.

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Detail Engineering, Construction Supervision and Pre-Commissioning activities must be

quoted with costs separately.
The existing Basic Engineering Package (in English) has been worked out internally due
to confidentiality. After awarding the contract, the Basic Engineering packed will be
provided to the Contractor.
In order to get a better overview about the scope of the project, Clariant offers a
separate meeting together with contractors in the inquiry phase, where contractors can
view the Basic Engineering package.
This work must be development in the Clariant Site in Coatza, then in the proposal must
consider to have a movil office with all the necessary for the engineering group like
computers, plotters, printers, movil sanitary, etc.
PROJECT SCOPE
The project EO & PO expansion project Coatzacoalcos has as principal objective the
capacity expansion of 900 ton / year by an installation a new production line R1170 for
ethoxylation and propoxylation purpose.
The new production line R1170 considers as basic design criteria to be the same as
production line R1160 (as well copy of production line R1120), capacities and control
concept, which have been improved and updated according to production experience
and risk & safety analysis.
The new production line R1170 will be installed in the existing production building, which
already considered an expansion for a new production line (space available in the
existing building).
For Propylene Oxide facilities, it is considered as design criteria to install facilities same
as existing one for Ethylene Oxide, in capacity and control concept. The new tank will be
installed in area already reserve for this tank.
The project scope considers the following items in existing facilities:
Reaction area:
Installation in existing operation building of a new production line 1170 for Ethoxylation &
propoxylation, consisting of a pre reactor with agitator, reactor loop (pump and heat
exchanger) and post reactor with agitator, full automatized (same state of art of
Coatzacoalcos control philosophy). In the existing production building the following
modification are considered:

Dismantling and relocation of existing caustic and acetic acid tanks installed in
the building to an external area.
Structural adjustment in the building for supporting of pre / reactor / post reactor
and peripheral equipment.

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Relocation of existing cable trays and conduits in free space for S-1170
installation. Will be checked if it is necessary and to coordinate with the supplier
for the E&I Engineering Detail assigned by Clariant.
Platform and secondary structural for piping, equipment and access to
equipment.
Adjustment of production building roof for reactor area.
Installation of fire fighting system for new reactor and adjustment of existing
installation.
Adjustment of existing manifold for interconnection of the new facilities with the
existing units.
Adjustment of existing header of the scrubber and interconnection of new
production line, railcar unloading and PO tank.

Vacuum system:
Rearrangement of the vacuum pumps for pre and post reactor vacuum system
respectively:
Adjustment of existing piping arrangement and tie in points for new pre and post
reactor.
Installation of a new catch tank and a new cooling circuit
Air cooling:
Expansion of air cooling facilities. 02 units. These units will be installed outside of the
production building, close by the existing air cooler units for the other production lines,
considering:
Equipment foundation
Relocation of existing area for cylinders storage
Pipe rack for piping support for cooling lines.
PO Tank:
Installation of a new PO Tank (120000 lts, 10 bar).
Adjustment of existing foundations
Installation of pipe racks and adjustment of Fire Fighting System
PO pipeline ring, insulated.

Unloading area:
Expansion of existing steel structural platform (around 20 m length)
Installation of additional loading arms for PO
Installation of PO pump, foundation preparation

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Utilities:
Tie ins for utilities and conections to new equipment have to be considered according
with the P&IDs. A list fo Tie ins will be created.
Cooling water, existing installation limited, new cooling tower, circulation pumps (02
units) and revamp of existing basin
Steam, capacity available.
Nitrogen, capacity available, option by expansion of facilities handled by third parties on
site.
Electricity, capacity available.

Definitions

Contractor: Party, which supplies the services to Clariant defined in this scope
definition.
Basic-Engineering: Existing documentation (attachment 3) which is the basis for the
execution of the project. The Basic Engineering will be provided by Clariant.
Detail-Engineering: Engineering work needed to undertake Construction,
Commissioning and Start-up of the unit, to reach production with designed capacity and
quality.
Mechanical Completion: Is the point in time, where the plant is mechanical, electrical
and structural finished. The plant is in principle ready for operation evidenced by function
tests. The system is ready to start COMMISSIONING activities.
Pre-Commissioning: Start-up of the complete unit or parts after MECHANICAL
COMPLETION with solvent or water and with all utilities / energies. Preparation of the
unit for Start-up. Only inert movement of material takes place at this point.
Operational Acceptance: Is the point in time, after MECHANICAL COMPLETION and
successful PRE-COMMISSIONING so that Clariant can confirm, that the plant under
operating conditions is in accordance with to the requirements.
Start-up: Will be performed by Clariant immediately after OPERATIONAL
ACCEPTANCE, to see if the plant will also work properly with chemicals and products.
Goal of this activity is to reach on-going operation and to meet production and quality
requirements.
Final Acceptance Test: Is the point in time after START-UP when the plant reaches
commercial production with the designed capacity and quality.

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Scope of Services

The scope of services includes:

Review of Basic Engineering Package

Project Management
Process-, Equipment-, Layout & Piping
Interaction with the E&I-Engineering Detail Supplier assigned for this
reach
Civil- Engineering
Construction supervision
Pre-Commissioning activities

Contractor is asked to perform the complete requested scope of services, which enables
Clariant to build the production unit and produce products with designed capacity and
quality.
Contractor supplies a project organization chart showing the responsible Project
Manager and the full-time assigned key members of the project team. These persons
are not to be exchanged during project execution. If necessary due to unforeseeable
reasons, replacement is jointly agreed.
Contractor ensures a close cooperation with the Clariant project team and the
designated production team. This includes an early information, co-ordination and
discussion with Clariant well ahead of all engineering-, procurement-, construction- and
pre-commissioning activities.
Contractor performs his work according to the current state-of-the-art of an experienced
Engineering company.
Contractor ensures a project execution according to the milestone plan of Clariant.
3.1

Project Management
Preparation of a Project Guideline covering all detailed aspects of co-operation
with Clariant (within 1 weeks after project kick-off)
Project-Management during the complete duration of the project until Start-up
Close cooperation with Clariant in particular with the Clariant Technical Project
Manager
Coordination of all Engineering activities according to the time schedule, cost
estimate and quality standards.

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3.2

Date: 30.03.2016

Coordination and Management of interfaces to external (third party) suppliers,

which are instructed by Clariant
Preparation and monthly update of a detailed project execution time schedule
based on the Clariant milestone plan in particular the critical path activities.
Contractor ensures the project execution according to the Clariant milestone
plan. Clariant will be immediately informed about changes. In case of delays,
Contractor will take action to overcome the delays in agreement with Clariant
Technical Project Manager.
Supervision of all construction and erection works
Preparation of a monthly status report and information of Clariant about the
project status (overall project status and schedule)
Calling in of periodic (e.g. weekly) project meetings incl. preparation of the
minutes
Organization of safety meetings incl. preparation of the minutes
Support of Clariant concerning permit request for authorities. Implementation of
changes due to requirements of the authorities.
Organization of all needed inspections, declarations etc. required for Mechanical
Completion.
Planning of Pre-Commissioning activities
Compilation of the As built Documentation

Process Engineering

3.3

Review and check of plausibility and consistency of existing Basic-Engineering

Documentation.
Thermic and hydraulic dimensioning of all not completely designed equipment.
Detailing of capable process parameters to check the warranty of Package Units
for performance tests.
Further development / detailing of the equipment list.
Detailing of P&IDs including all required revisions.
Preparation of interconnecting P&IDs, if required.
Tie ins for conections to new equipment have to be considered according with
the P&IDs. A list fo Tie ins will be created.
Design the PO (Propilene Oxide) dossing to the existing reactor R-1160 and R1110
Update of drawings.

Equipment, Machines, Package Units

Review, completion and detailing of all existing equipment, machines and

package unit specifications pending.

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3.4

3.5

Date: 30.03.2016

Preparation of specifications and requisitions for procurement of all equipment,

machines and package units pending. Remark: Long lead time items (e.g.
vessels with long delivery time will be specified and ordered during the BasicEngineering by Clariant.
Definition of details for quality inspections at suppliers.
Review, check, revision of equipment drawings, calculations and documents
received from suppliers. Immediate forwarding of supplier drawings (2) to
Clariant for review.
Preparation of an equipment list with all required inspections of pressure vessel
and other safety related equipment.
Preparation of spare part list according to recommendation of supplier/delivering
times
Preparation of documents for equipment installation with isometric projections of
the equipment (incl. connections list and technical generated by the 3D-model
Update of drawing lists
Preparation of specifications and requisitions for procurement for Installation of :
- equipment
- Insulation of equipment
- Paintwork
- Labeling of equipment

Layout Planning
Design of a 3D-model (Navisworks) as main basis for equipment arrangements,
site layout, piping and construction.
Integration of Civil-Engineering details into 3D-model
Integration of main trays and junction boxes from E&I Engineering into 3D-model
Creation of detailed arrangement plans for package units, apparatus, pumps etc.
Generation of loading data as basis for civil engineering
Close cooperation of layout planning with Civil Engineering activities

Piping
The 3D-plant-model is basis for piping. All pipes ( 2 inch) have to be designed
using Intergraph, Smartplant 3D or equal software and included into the 3D-plant
model.
Tie in design and MTO.
Pipe routing plans are created (with pipeline routes, pipe arrangements)
Organization of regular piping review meetings with Clariant. Contractor presents
the status of piping on the basis of the 3D-model. Clariant reserves the right to
check every single pipe prior to release for construction.
Creation of 3D-piping-standards based on Clariant piping classifications and
standards.
Complement piping specifications for example 600 # for PO pipe.
Update of a pipe list including pipe-identification-number, diameter, medium, pipe
class code, max. Operating temperature, insulation and heating requirments.

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Documentation of all required calculations (e.g. stress calculation)

Generation of isometrics for construction and at the end for As built for pipes 1
inch incl. parts lists. Specification of required pipe supports.
Construction, calculation and documentation (list and datasheets) of all required
special parts and special supports
Calculation of loads for floating and fixed supports
Specification, Calculation of compensators
Preparation of material lists (MTO) for purchasing
Preparation of specifications to requisitions for procurement:
o Pipe installations
o Pipe insulation
o Pipe labelling
o Pipe pre-fabrication
o Painting
o Special parts
o Special supports
o Safety valves and other safety installations
Update of drawing lists

3.6
Electrical & Instrumentation Detail Engineering
Electrical and Instrumentation Detail Engineering is not part of this scope but it will be
necessary to work closing with the supplier assigned by Clariant for this reach.

3.7
Civil Engineering
The scope of civil Engineering work consist of all activities needed to design, supervise
construction:

Foundation design
Chemical and Pluvial drain design
Road design
Structural Calculation.
Piping / Electrical support design
Secondary steel structural design.
Concept catalogue / Description for construction activities.
Regular review meetings with Clariant and Engineering project team
All civil / structural documentation must be done according to local regulation, site
conditions and soil survey

Basically requested are architecture and design as well as civil engineering, services
relating to soil mechanics, earth works and foundation engineering.
The Activities are listed by six consecutives project phases:

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3.7.1

Review of existing Preliminary Design

Check of existing preliminary concept
Preparation of missing preliminary drawings (plans, section and level views etc.)
Support of meetings with authorities
Scheduling of all Civil Engineering activities in accordance with main project time
schedule.

3.7.2

Final Design
Final and detail design on basis of Preliminary Design in close co-operation with
Process-, Layout-, E&I-Engineering and authorities
Preparation of all needed drawings and review by Clariant (Detail and working
drawings, plan of floors, steel structure incl. steel work details etc.)
Regular review meetings with Clariant and Engineering project team
Structural Calculation
Detailed scheduling of all construction activities in accordance with main project
time schedule.
Selection of materials
Building Permission Application, prepare all submission documents for approval
regarding architecture and civil engineering
Submission of documents

3.7.3

Execution drawings
Detailed work in drawings on a scale of at least 1:50 (see also 3.7.5)
Establishing of other specialists plannings

3.7.4

Preparation of Procurement
Calculation and projection of needed quantities of services and materials
Preparation of specifications and requisitions for procurement

3.7.5

Construction Supervision
Coordination and supervision of all construction activities in accordance to legal
requirements, the Clariant work permits, Detail-Civil-Engineering, the technical
state-of-the-art rules
Supervision of all construction activities and ensuring the accordance to project
time schedule. In case of delays countermeasures are proposed to reassure the
time schedule.
Final approval for construction of all detail and working drawings (i.e. formwork,
reinforcement drawings etc..)
Issuing of a weekly detailed construction progress report
Perusing of scope changes in close co-operation with CLARIANT.
Close co-operation with project manager of CLARIANT and CONTRACTOR in
order to meet time and cost frame
Ensures the accordance of construction with legal requirements, the permits,
Detail-Engineering, the technical state-of-the-art rules
Organizing regular construction meetings.

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Guarantees to meet the legal and CLARIANTs safety and hygiene regulations for
construction sites.
Initiating of Punch List inspections after completion of construction activities.
Initiating and supervision of completing Punch List items.

3.7.6 Documentation
Preparation of documentation as built.
3.8
Checks of incoming Deliveries from Suppliers
CONTRACTOR checks all incoming deliveries from suppliers. CONTRACTOR accepts
all deliveries by signatures on the delivery documents, checks the deliveries for
completeness, defects, accordance with specifications and passes on the signed
delivery documents to CLARIANT.
In case of incompleteness or defects of deliveries CONTRACTOR informs immediately
CLARIANT for claiming guaranties or fulfillment of delivery.

3.9
Construction Supervision
CONTRACTOR provides Construction Management and Supervision to ensure a timeschedule-conform, cost-conscious, high quality and safe construction of the unit.
Construction Management and Supervision includes:

Preparation of specifications for requisitions of scaffolds, lifting equipment and

construction site infrastructure
Detailed scheduling of all construction activities taking into account delivery
times and master time schedule.
Coordination and management of all construction activities needed to erect the
unit.
Supervision of all construction activities (equipment, piping, insulation and
painting) and ensuring the accordance to project time schedule. In case of delays
countermeasures are proposed to reassure the time schedule.
Issuing of a monthly detailed construction progress report
Close co-operation with project manager of CLARIANT and CONTRACTOR in
order to meet time.
Ensures the accordance of construction with legal and Clariant requirements, the
Clariant work permits, the technical state-of-the-art rules in close co-operation
with the Engineering team.
Organizing regular construction meetings and preparation of the minutes.
Guarantees to meet the legal and CLARIANTs safety regulations for construction
sites.
Initiating of Punch List inspections after completion of construction activities.
Indication and documentation of deficiencies. Initiation or remedial action.
Documentation and reporting of construction activities.
Initiating and supervision of completing Punch List items.
Initiating and supervision of legal inspections.

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Perusing and evaluation of scope changes from Contractors in close cooperation with CLARIANT project manager.
Ensuring of good housekeeping and safety on site.
Records of all pre-commissioning activities.

3.10 Pre-Commissioning
PRE-COMMISIONING is performed under the direction of the CONTRACTOR after the
construction of the unit is completed. The error-free functionality of the unit has to be
proven.
Contractor works out a detailed pre-commissioning in close co-operation with Clariant
project team. The pre-commissioning plan is to be prepared well ahead the start of the
pre-commissioning activities.
Contractor ensures a complete documentation of all pre-commissioning activities.
The CONTRACTOR has to follow that Clariant Commissioning Guide.
3.11 Start-up
After receiving the OPERATIONAL ACCEPTANCE the unit is handed over to
CLARIANT for start-up with chemicals. Support may be needed by the CONTRACTOR.

Documentation

After MECHANICAL COMPLETION the Documentation as built is handed over to

CLARIANT according to attachment 2 (three paper-copies and one electronic copy
including P&IDs, Equipment arrangement plans etc.).
After OPERATIONAL ACCEPTANCE the records of the PRE-COMMISSIONING as well
as updates occurred during PRE-COMMISSIONING are being incorporated into the
Documentation.
This final Documentation as built is handed over to CLARIANT three weeks after
OPERATIONAL ACCEPTANCE.
The documentation has to be written in English/Spanish language.
All software tools and layouts of documents intended to be used by the Contractor have
to be accepted by Clariant prior project start.
The following software shall be used:

MS Office (2010), for all written texts, spreadsheets and graphics

MS Project (2003 or higher), for time schedules
AUTOCAD, for PIDs
Naviswoks, for the 3D model

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5.

Date: 30.03.2016

Guidelines, Standards and Regulations

In general the plant has to be designed according to the latest editions of all relevant
laws, Guidelines, Standards, Regulations, legal directives.
All design must be conform with regulations and best engineering practises.

Attachment 1: Important project milestones

Award of contract:

15.04.2016

Start Detail Engineering:

15.04.2016

30% Model Review

29.04.2016

60 % Model Review

16.05.2016

Civil package for construction

30.05.2016

Isometrics & MTOs for quote

20.06.2016

Final Detail Engineering Package

15.07.2016

Attachment 2: Documentation
Project Management
Meeting minutes and status reports
Time schedule (target/actual comparison)
Minutes of safety meetings
Process Engineering
Thermic and hydraulic design calculations of equipment
Specification of Package units
P&I Diagrams (electronic copy in AutoCad, for further use by Clariant) including:
all equipment according the equipment list (numbered)
specifications with details of allowed temperature, pressure, material,
main measures, supplier and inventory number
all piping incl. insulation and gradients
fittings, venting, draining, sampling
safety valves and other safety equipments
electrical and instrumentations with numbering

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location (level) of equipment

Motors with all data and numbering
Safety valves list
Drawing lists

Layout Planning
Layout plans
3D Model (electronic copy in Naviswoks, for further use by Clariant)
Equipment, Machines, Package Units
Detailed equipment list
Pump list
Detailed specifications of all equipment, machines, pumps and package units
Spare list according to recommendations of suppliers
Procurement documents (delivery documents, protocols of acceptance)
List of equipment
Maintenance plans
Equipment list with all required inspections of pressure vessel, elevator and other
safety related equipment.
Compilation of the suppliers documentations
Drawings of suppliers
Documents of technical inspections
Piping
Pipe list including pipe-identification-number, diameter, medium, flow rate, design and
operating pressure/temperature, insulation and heating.
3D pipe standards
Pipe calculations (pressure drop, stresses etc.)
Records of pressure and tightness test
Specification, calculations and drawings of pipe brackets, loads for floating, fixed
supports
Specification and calculation of compensators
Material lists
Isometrics as built with all support points
List of isometrics
Procurement documents (Purchase order, acceptance of order, correspondence,
scope of changes, delivery documents, protocols of acceptance)
Documentation pressure vessel (description, calculation and test base, pipe
standards, fluid-class, category, attestations, risk analysis, operating instructions,
declaration of conformity)
documentation of suppliers, material documents
certificate of installation including quality attestations of the suppliers (e.g.
concessions, welding attestations, certifications)

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Civil Engineering
Minutes of meetings, protocols, status reports
Specification of the building structures
Detail and working drawings, reinforcement drawings, foundation drawings as
build
Plans of floors, sections, elevations, all Detail drawings
Building permission Application
Bills of quantities
Loadbearing structures, static calculations and execution drawings
Drawings and permissions regarding fire-prevention
Steel structure and steel work detail plans
Dimensioning, specification of heating and air conditioning
Protocols of acceptance

Construction Supervision
Installation certificates

Pre-Commissioning
Records of inspection of conformity to P&I Diagrams and Design
Records of rotation tests, cold alignments, material checks
Installation records of safety devices
Records of cleaning and drying of piping and equipment
Documentation of point to point checks and loop-checks
Inspections documentation
Grounding records
Acceptance of Mechanical Completion

Operational Acceptance
Record of Operational Acceptance

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Attachment 3: Existing Basic Engineering Package

The Basic Engineering package contains the documents:

Project Scope and Description

site conditions
equipment list
line list
P&I-Diagrams
pipe classes (Clariant standard)
site layout plans and layout study of equipment
equipment data sheets (EDS) with process data, for vessels
information on hazardous areas
instrument list with process data
instrument data sheets
motor list
Topographical study
Soil survey

Attachment 4: P&IDs and Layouts

Attachment 5: Equipment list and spacifications data sheets
Attachment 6: Piping List

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